Aprilia RS250 Project

[MK3 Dan]

chippy348 said:

I have seen lots of RGV250 cylinders, and that cylinder looks bad !

Athena now have had the cylinders made, may not fit with your budget but i have these in stock if time scale is a issue.

The Cranks on the RGV/ RS 250 are not the strongest when new, although they were never made to be rebuilt can be rebuilt with care. The center section is pressed together but also welded which makes is tricky, i have seen some shocking attempts !

Let me know if you need help with the crank and such

Doesnt look great does it!

Hopefully can be replated if not will look at options, in the trade so hopefully find something at a sensible price.

Understood on the crank, hence my comments in the last post, think new will be the way forward, especially with my pricing.

[MK3 Dan]

alvington89 said:

https://www.all-strokes.com/product-page/aprilia-r...

https://www.rimotoshop.com/gb/chains-ridges-roller...

Thanks but it is the chain guide I am after, not the chain guard - plan to fit the Tyga carbon rear hugger/chain guard for that.

Ordered the eBay chain guide for now so will see what that looks like once it arrives.

[MK3 Dan]

Steve Bass said:

If new cranks are available, I’d definitely take that route. Not cheap but refurbishing an RS never is. I think that’s the key problem here, over their lifetime, the RS needed constant attention, fettling and $$$, something that the average owner couldn’t afford.
This will be an expensive project but the end result will be something very few bikes can get close to… perhaps don’t think of it as an investment

Thanks Steve (will be saying that a lot more in this topic I am sure!)

New crank it will be then.

Ordered pistons today so they should be here Monday and will send Sean an e-mail shortly. Have noted a 10% discount on forum contributors so will do that.

Yeah, well over the investment side and now just going for the best I can. Still don't think it will loose as much as my other projects, providing I keep it for a few years.

[MK3 Dan]

Managed to get a weekend a good few hours on it over the this weekend.

Started with a cleaned up frame. Wanted to improve the shine more but with it being coated/anodised it wouldn't polish up any further.



Got the swingarm all built up with brand new bearings and the Chinese chain guide which finally landed, it seems half decent quality and fits well. Guess time will tell how well it lasts but it was my only option.



Replaced all the bearings in the rear suspension linkage, along with seals. It did not look too happy and few bits of rust on some of the spacers.





Frame and swing arm joined back up:



Replaced the head stock bearings as well, whilst they didnt look too bad they were some signs of wear and I am glad I made the decision to do all of the bearings whilst I was at it.





Got her back up on some stands



Went over the wheels, still want to put a protective coating of some sort on them but was getting carried away with progress. First lot of titanium went on with the disc bolts and rear sprocket bolts - plus a new sprocket. I always think Renthal sprockets look good.



That was how Saturday ended!



Today started with cleaning up and refitting the undertray, along with ECU and CDI



Then cleaned up and sat the wiring loom back in





End of a few hours today



Tucked it up under a new to me cover



Overall happy with the progress and things are cleaning up well. Still plenty to keep me going but lots of bits I dont want to bolt in without the engine, yet to send the cylinders which will go next week so won't see them back until the New Year.

Cleaning the worse barrel up it looks like the plating has come off the bore, not sure if this is due to running lean or a lack of oil. Both carbs and oil pump will be checked/cleaning with new oil and fuel pipe - plus replacing the check valves in the cases and cylinders.

[MK3 Dan]

NITO said:

Great find for you there, good luck with the rest of the build and nice work.

I had some of the same issues as you, the seized hugger bolt for example!

I expect your carbs may be a similar story to mine. Be careful with the high power circuit elbow off the right hand carb as it is unobtanium now. My left one snapped with next to no pressure through being weakened by ethanol fuel, (it was all clogged up also), which did a lot of damage to the carbs where it had been stood and thankfully I went through them all before daring to take the bike down the road which picked up a lot more issues too with other parts! you're doing the right thing with this approach.

I did a blog for my own sanity documenting it all here in case you find anything there useful;
https://nitosport.com/category/aprilia-rs250-chest...

Edited by NITO on Monday 27th November 14:40

Thanks for the info and interesting to take a read through your blog.

I had been warned about the float levels and its interesting to see some pictures and the process that you followed.

I am hoping things are ok on the Ethanol front, it hasn't been on the road here and know its when it was running super was used. Petrol tank doesn't appear to have swollen and that is apparently more of a thing with Silver tanks!

[MK3 Dan]

Got the crank out of the engine during the week and despite all the bearings feeling ok I am going to replace it with a new one.



Also decided at that point that there really isnt too much too these engines and I may as well take it completely apart to clean it up and check over the gearbox and clutch.

Cassette gearbox makes things nice and easy. It looks in really really good condition, next to no wear on the dogs.

Clutch also looks good, just the steel plate has a groove worn in it from the (I presume) anti judder washer so going to replace that.



Will get an oil pump gasket and output shaft gasket sorted next week then get all the bottom end together, waiting on the crank and cylinders.

Cylinders went away early this week with new Pro - X pistons to Sean at Tuning Works who has been mega helpful.

Hopefully have a few hours to tinker with the bike again tomorrow but will be doing lots of smaller jobs so won't see much visual progress.

Start of the Cerakote should be back next week so I can get the clip ons and top Yoke etc on.

[MK3 Dan]

lard said:

seeing that frame being cleaned up reminded me of my RS125 I had many years ago, my first and best handling bike!, always coverted the RS250 and loving the progress, thanks for sharing

Likewise, had a RS125 a fair few years ago and always wanted one of these.

[MK3 Dan]

Ordered up the replacement crank this week - due in Feb :-( from what I understand Suzuki are having a batch made.

Did have some parts arrive back this morning though, had some smaller parts blasted:



Along with the cylinder heads:



The foot pegs and kickstarted have been blasted and then clear Cerakoted:





Clip on's, top yoke and rear hanger Cerakoted, along with a box of small parts:







As mentioned early on in this thread, the clip on's do seem to weigh alot. I don't have anything here to compare them to at the moment though.



I had told myself not to get too carried away with this but I have since ordered up a lot more titanium bolts and now that there is a delay on the crank coming through I may get the engine cases blasted as well and some more smaller bits off the bike.

Still hopefully plenty of time to get this done before next summer, although getting it registered is still a slight worry having not done this before. Quite fancy the Aprilia Factory track day and maybe the classic bikes 2 stroke one so if there are any hold ups on the road side I will still get out on it.

[MK3 Dan]

Marquezs Stabilisers said:

Most super has ethanol in it now, if you see E5 on the pump that means 5% ethanol. Only solution is either get the plastic tank Caswell lined (for which I'd send it to them having done it myself), or get a race spec alloy tank. If these were run at the TT someone somewhere will have made one.

Food for thought, thank you.

Thought I heard that the Esso stuff was still ethanol free but this might have changed recently.

Guess it's a decision if I risk it with Super, get the tank coated (although this always makes me nervous) or consider running a race fuel for the limited mileage I will be doing.

[MK3 Dan]

Marquezs Stabilisers said:

Esso themselves saying on their website up to 5% ethanol. When I had a plastic Acerbis made tank as OE on my Ducati, I emailed basically all the fuel companies. Shell V-Power and Sainsbury's Super at the time both confirmed ethanol. BP Ultimate is also up to 5%.

Thanks for the info, I will have to make a decision nearer the time.

Not keen on draining the tank each time as whilst I wont be using it much, as in not doing lots of miles, I do want to use it ever few weeks through the summer if the weather allows.

[MK3 Dan]

alvington89 said:

The clip on's will be weighted at the ends as this helps the handling.

That is without the bar end weights though, that is the weight of a completely bare clip on?

Bar end weights are additional again!

[MK3 Dan]

Got the freshly coated top yoke and clip on's fitted last weekend.









Placed another order for a batch of titanium bolts tonight - dread to think how much I have spent on them!

Crankcases completely stripped and away for blasting, should have them back before the Christmas break so can at least get the bottom end together whilst waiting for the crank and barrels to land.

[MK3 Dan]

Birky_41 said:

Attention to detail is spot on with this one! That will be like a show piece when you finish

Wish I had the patience to be that in detail with mine

Thanks, knowing it isn't particular low mileage or going to be completely original means I can still use it without too much concern. Let me know if I can do anything when you get on yours. I can get some discount on most parts, particularly engine stuff. Also just a heads up if you are thinking of replacing the crank Suzuki are currently making a batch and not sure if they will be making more after that, they will be ready early Feb and will most likely come with a decent price increase so get your order in now if so!

ChocolateFrog said:

Brilliant.

The RS250 was almost mythical to me when I was 17.

Very rare sight on the roads but I used to go to my local Aprillia dealer just to gawp at one and dream.

Remember in my early teens when a Dad's friend had one locally, used to always be over when I heard his garage being opened. As with everything like this wish I had got one when I first passed my test as would have been a good investment, although would have struggled to afford to keep it going.

Twolane said:

Great work so far, its easy to get carried away with the £££ ,best not keep count...
Is the gearbox output spline ok, they have a habit of wearing?
Had to replace mine on the RGV.

Keeping a stash of receipts but not going to add them up, although still think I could sell this without a lose currently - which rarely happens with a project like this!

I had a quick check when removing the sprocket and didnt notice anything, will double check thank you.

Barrels are done so popping to The Tuning Works to collect them in the morning.

Cases should have been blasted yesterday morning so hopefully over the Christmas break I can get the bottom end back together, just waiting on that crank in early Feb,

[MK3 Dan]

Birky_41 said:

Messed up with me reply there. For some reason I'm not chocolate frog. I'm too thick to work out how to fix that but that was me replying

Will drop you a PM so you have my details, even with pistons, rings, gaskets etc I should be able to help. Looking forward to seeing your progress!

[MK3 Dan]

Had a go at rebuilding the rear brake caliper at the start of the week, having never done one before thought it best to start with the rear as less to go wrong and easier to sort if I make a mistake but it was surprisingly easy and all went together well. All back on the bike and bled through, works well and isn't leaking any fluid (yet!).







Also got the crankcase back from blasting this morning, they have come out amazing!

Before:





After:







Collected the barrels from Sean at the Tuning works at the start of this week and had a chat with him, he has sold me on the Zeltronics once I get it up and running.

Will get some pictures of the barrels but they have come up well, like the cases and heads, so the engine should look great when it goes together.

Will get the bottom end back together and the barrels built up over the Christmas break so I am ready for when the crank finally arrives - although if the Feb date drops off any further I will be tempted to get it back together with the old crank and then replace it at a later date.

[MK3 Dan]

Krikkit said:

Those cases look mega, do you know what they were blasted with?

Re: Brake calipers it's easy when the calipers and seals etc are decent quality, Brembo are really good at both.

They have been aqua blasted and then clear Cerakoted.

They will go through a hot wash a number of times and all the oil drillings etc thoroughly cleaned out - you have to be careful of any debris left behind.

Yeah, used Brembo seal kit and was surprised how easily it all went together!

[MK3 Dan]

Thanks Steve,

Think it was you that mentioned it originally, any clues on where your ignition pulse generator came from?

I see it can run the quick shifter, have you tried this?

[MK3 Dan]

Spent today making as much progress as possible on the engine without the new crank:

[MK3 Dan]

Ha, thanks Steve, send the engine over and I will get on it!! Quite enjoying the rebuild and always nice when it looks good!

Will look at the gears but will start as it is, already strecthing the budget, will see how we go.

The tuning works do the plugs for Zeltroric so its plug and play, no excuse not too really!

Started on the tank this week, no photos but had the tank out and gone through, tap built up with petrol gunk so an easy clean to get it working. Paint was bad but dropped at a bodyshop this morning and a few seconds with a mop showed it should be good once properly gone through. Mould cleaned off the bottom after I taped it up so could steam.





Gave the carbs a clean up and found alot of gunk in the float bowl, again mostly good through just some rubbish from it sitting







Fuel cap was a mess so stripped and sent off for blasting/painting



Random Japanese sweet wrapper found when stripping down the seat unit!



Started looking at fairing panels before they went away for paint!





Had supervision from a furry friend!

[MK3 Dan]

Tried cleaning up the front calipers but had no luck, started removing paint without removing all the dirt so they have gone to be Cerakoted too!

Carbon rear mudguard and sprocket cover should be delivered this week.

Still waiting on the crank which is showing 'delayed' with Suzuki so hope that shows up soon, its my biggest halt in progress!